Caterpillar Cat 215 EXCAVATOR (Prefix 95Z) Service Repair Manual Instant Download (95Z00001 and up)

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(HEB... 1/12 Product: EXCAVATOR Model: 215 EXCAVATOR 95Z Configuration: 215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE Disassembly and Assembly 3304B and 3306B Engines for Caterpillar Built Machines Media Number -SENR5598-09 Publication Date -01/01/2013 Date Updated -25/01/2013 i00886792 Governor - Disassemble SMCS - 1264-015 Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 1P-0510 Driver Group 1 B 6V-2163 Spring Clamp 1 C 1P-1855 Retaining Ring Pliers 1 Start By: A. Remove the fuel injection pump housing and the governor. Refer to Disassembly and Assembly, "Fuel Injection Pump Housing and Governor - Remove". Note: To remove the governor for the disassembly of the fuel injection pump housing, perform Steps 1, 2, 16, 22, 24, 25, 26, 27, 30, 32 and 34. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(HEB... 2/12 Illustration 1 g00453006 1. Remove fuel ratio control (1) from governor (2) . Illustration 2 g00453007 Note: Illustration 2 shows the fuel ratio control that is still connected. 2. Remove six bolts (3), two bolts (5), housing (4) and the gasket. Illustration 3 g00453008 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(HEB... 3/12 3. Remove governor spring (7), seat (6) and the washers. Illustration 4 g00453009 4. Remove six bolts (8), cover (9) and the gasket. Use Tool (A) in order to remove seal (10) . Illustration 5 g00453010 5. Remove low idle adjustment screw (12) and spring (11) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

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215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(HEB... 4/12 Illustration 6 g00453011 6. Remove shaft assembly (15) and levers (14) and (13) . Illustration 7 g00453012 7. Remove two snap rings (19) from two pins (17). Remove two pins (17). Remove plates (16) and stop (18) . Illustration 8 g00453014 8. Remove pins (21) and (22) and remove spring (20) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(HEB... 5/12 Illustration 9 g00453015 9. Remove two bolts (23), and the washers, and remove adapter (24), the coupling, and the O- ring seal. 10. Remove contact (27) and body (28) with an O-ring seal. 11. Remove two bolts (29) and the washers and remove cover (30) and the gasket. 12. Remove two nuts and washers (26) and remove shutoff solenoid (25) and the gasket. Illustration 10 g00453016 13. Remove shaft (31) and lever (32) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(HEB... 6/12 Illustration 11 g00453017 Note: The check valve will be damaged during removal. Remove check valve (33) only if a replacement is necessary. 14. Remove check valve (33) only if a replacement is necessary. Illustration 12 g00453018 15. Remove seal (34) and adjustment screw (35) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(HEB... 7/12 Illustration 13 g00453019 16. Remove bolt (36), housing (37) and the gasket from the fuel injection pump housing. Illustration 14 g00453557 Typical example 17. Remove bolts (38) and remove torque control (39) . 18. Disassemble torque control (39) and inspect the spacer, the spring, and the insulator for damage or wear. Replace parts that are worn or damaged with new parts. Illustration 15 g00453558 19. Remove two bolts (40) and block (41) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(HEB... 8/12 Illustration 16 g00453559 20. Remove the bolt that holds collar (42) to bolt (44). Remove collar (42), spring (43) and bolt (44) . 21. Remove the stop screws from collar (42) if the collar needs to be replaced. Illustration 17 g00453560 22. Remove three bolts (46) and remove governor servo (45). The governor servo must be rotated in order to be released from the rack's regulator. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(HEB... 9/12 Illustration 18 g00453632 23. Remove lockring (50), seat (53), link spring (52) and sleeve (51). Remove the other lockring (50) from the groove in the center of valve (47). Remove valve (47), sleeve (48) and piston (49). The piston must be pushed down in order to be removed. Remove the O- ring seal from sleeve (48). Remove pin (55) and lever (56) . Illustration 19 g00453633 Illustration 20 g00453634 24. Use Tool (A) in order to hold spring (58) compressed for the removal of ring (57). Spring (58) is used in order to put a preload on the thrust bearing for the camshaft in the fuel injection pump housing. 25. Remove ring (57) and slowly release Tool (A) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(H... 10/12 Illustration 21 g00453635 26. Remove bearing (60), sleeves (59) and spring (58) . Illustration 22 g00453636 27. Remove ring (61) and dashpot assembly (62) . Illustration 23 g00453637 28. Use Tool (C) in order to remove snap ring (68). Remove ring (67) and spool (66) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(H... 11/12 29. Remove seat (65) from spring (64) and remove spring (64) from seat (63) . Illustration 24 g00453665 30. Remove riser (69) . Illustration 25 g00453667 31. Remove ring (70), races (71) and bearing (72) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(H... 12/12 Illustration 26 g00453668 32. Remove four bolts (73) and carrier (74) . Illustration 27 g00453669 33. Remove dowels (77) and flyweights (76). Remove governor shaft (75) and the dowel that is not shown from shaft (75) . Illustration 28 g00453670 34. Remove races (78) and bearing (79) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(HEB... 1/17 Product: EXCAVATOR Model: 215 EXCAVATOR 95Z Configuration: 215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE Disassembly and Assembly 3304B and 3306B Engines for Caterpillar Built Machines Media Number -SENR5598-09 Publication Date -01/01/2013 Date Updated -25/01/2013 i01111261 Governor - Assemble SMCS - 1264-016 Assembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 1P-1855 Retaining Ring Pliers 1 B 6V-2163 Spring Clamp 1 C 1P-0510 Driver Group 1 D 6V-2054 Shield Driver 1 Note: Put clean engine oil on all parts before assembly. Ensure that all of the oil passages are clear. Note: Check the condition of the gaskets and the O-ring seals. If the gaskets, the seals, or any parts are worn or damaged, use new parts for replacement. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(HEB... 2/17 Illustration 1 g00453799 1. Install one race (1), bearing (2) and the other race (1) on the camshaft in the fuel injection pump housing. Illustration 2 g00453801 2. Put flyweights (4) in position on carrier (3) and install the dowels in order to hold the flyweights in place. The flyweights must move freely on the dowels. Illustration 3 g00453802 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(HEB... 3/17 3. Install dowel (5) in governor shaft (6) and install the governor shaft in the carrier (3) . Illustration 4 g00459340 4. Put carrier (3) in position and install bolts (7) . Illustration 5 g00459410 5. Install race (9), bearing (10) and race (9). Use Tool (A) in order to install ring (8) on riser (11) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(HEB... 4/17 Illustration 6 g00459411 6. Install riser (11) . Illustration 7 g00459414 7. Assemble the dashpot, as follows: a. Install spring (13) on seat (12) and install seat (14) in spring (13) . b. Put spool (15) and ring (16) in position on seat (14) and use Tool (A) in order to install snap ring (17) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(HEB... 5/17 Illustration 8 g00459416 8. Install dashpot assembly (19). Install ring (18) in the lower groove in the governor shaft. Illustration 9 g00459419 9. Install sleeve (20), spring (22), sleeve (20) and bearing (21) . Note: Spring (22) is used in order to put a preload on the thrust bearing on the camshaft in the fuel injection pump housing. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(HEB... 6/17 Illustration 10 g00459421 10. Use Tool (B) in order to hold spring (22) compressed and install ring (23) in the groove in the governor shaft. Remove Tool (B) . Illustration 11 g00459423 11. Put lever (33) in position on the governor servo and install pin (32) in order to hold the lever in place. Use a hammer and a chisel in order to move the metal (stake) at four places that are spread apart 90 degrees. Perform this procedure on the outside surface on both legs of the governor servo. This helps to hold pin (32) in place. 12. Install the O-ring seal on sleeve (25). Install piston (26) and sleeve (25) . 13. Install valve (24) . 14. Install one lockring (27) in the groove near the center of valve (24). Put sleeve (28), link spring (29) and seat (30) in position on valve (24) and install second lockring (31) . Illustration 12 g00454273 15. Put the governor servo in position on the fuel injection pump housing with piston (34) that is engaged over rack control sleeve (35) and install the bolts that hold the rack control sleeve in place. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

215 EXCAVATOR 95Z00001-UP (MACHINE) POWERED BY 3304 ENGINE(HEB... 7/17 Illustration 13 g00591527 3304B engine Note: The 3304B engine has one stop screw (36) and one locknut (38). Illustration 14 g00454274 3306B 16. If the stop screws were removed, install two stop screws (36) in collar (37), as shown. Install locknuts (38) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/10/10

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